Liner For Construction Material Container

ABSTRACT

A liner for protecting the interior of a construction material container is provided to have a shape complementary to that of a joint compound container. The liner is formed of a lightweight, flexible and disposable material and can be positioned directly within the joint compound container. In use, the joint compound is placed directly within the liner disposed within the container. After one or more uses of the container including the liner, the liner, along with the build-up of hardened joint compound or other construction material placed within the liner, can be removed from the container and disposed of. A subsequent liner can then be positioned within the container to enable continued use of the container without the need for removing and remaining construction material therefrom.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application claims priority from U.S. Provisional Patent Application Ser. No. 62/732,096, filed on Sep. 17, 2018, the entirety of which is expressly incorporated herein by reference for all purposes.

FIELD OF THE DISCLOSURE

The present disclosure relates generally to joint compound, and more specifically to containers for use in holding joint compound for use.

BACKGROUND OF THE DISCLOSURE

In the area of construction, often drywall or a similar wall structure is utilized for the construction of interior wall surfaces within a building. Once the drywall has been secured over the wall studs to provide the exposed interior surface of the wall, the seams between the different sections of drywall must be covered using a joint compound or similar material. The material is spread over strips of tape positioned over the seams between drywall sections and spread evenly until the compound is relatively smooth to provide a desired appearance to the exposed surface of the wall.

The joint compound is formed to harden quickly such that soon after application the joint compound forms a hard coverage over the tape and drywall seam. Once completely dry, the joint compound is sanded or otherwise smoothed to provide a seamless surface for the drywall section and the interior wall formed thereby.

Due to the quick drying nature of the drywall compound, one significant issue with the use of the drywall compound is the manner in which it is carried to and applied onto the drywall.

As drywall is utilized in a variety of interior locations, it is most often the case that the compound is placed within a hand-carried container which is transported by an individual to the sections of drywall to be covered. The size of the container is designed such that it can be easily carried into a variety of locations by the individual, such as to an elevated location on a ladder where the container can be held or otherwise positioned for use by the individual. The individual can use a mud knife or trowel, or similar device to scoop the joint compound out of the container and apply it to the wall where desired.

However, due the quick drying nature of the joint compound, the compound must be applied quickly in order to avoid the joint compound prematurely hardening within the container. Further, regardless of the speed of application of the joint compound to the drywall by the individual, the shape of the container prevents the mud knife from effectively reaching all of the joint compound placed within the container. As such, the joint compound remaining in the container hardens and become difficult to remove. On many occasions, as the container is repeatedly utilized, a significant build-up of the joint compound develops and cannot be removed, resulting in the requirement for rigorous cleaning measures or premature disposal of the container.

Therefore, it is desirable to develop an improved container that can address these issues with the prior art.

SUMMARY OF THE DISCLOSURE

According to one aspect of an exemplary embodiment of the invention, a liner is formed to have a shape complementary to that of a joint compound container. The liner is formed of a lightweight, flexible and disposable material and can be positioned directly within the joint compound container. In use, the joint compound is placed directly within the liner already disposed within the container. After one or more uses of the container including the liner, the liner, along with the build-up of hardened joint compound or other construction material placed within the liner, can be removed from the container and disposed of. A subsequent liner can then be positioned within the container to enable continued use of the container without the need for removing and remaining construction material therefrom, saving significant time and expense.

These and other aspects, features and advantages of the invention will be made apparent from the following detailed description taken together with the drawing figures.

BRIEF DESCRIPTION OF THE DRAWINGS

The drawings illustrate the best mode currently contemplated of practicing the present invention.

In the drawings:

FIG. 1 is an isometric view of a container including a liner according to an exemplary embodiment the invention; and

FIG. 2 is a cross-sectional view along line 2-2 of the container and liner of FIG. 1 according to an exemplary embodiment the invention.

DETAILED DESCRIPTION OF THE DRAWINGS

Before the present compositions, apparatuses and methods are described, it is understood that this invention is not limited to the particular embodiments and methodology, as these may vary. It is also to be understood that the terminology used herein is for the purpose of describing particular exemplary embodiments only, and is not intended to limit the scope of the present invention which will be limited only by the appended claims.

Referring now to FIG. 1, the reference numeral 10 generally identifies an illustrated exemplary embodiment of a container utilized to hold an amount of a joint compound, stucco, exterior insulation finish system (EIFS) application material, paint, varnish, caulk, adhesive, bonding material, petroleum or solvent therein. The container 10 can have any desired shape and includes a bottom wall 12 and a number of side walls 14 joined to one another and extending upwardly from the bottom wall 12 to form an interior 16 of the container 10. The container 10 is preferably formed of a lightweight but rigid material, such as a metal or hard plastic, in order to hold the weight of the particular construction material positioned therein.

Looking now at FIGS. 1 and 2, a liner 18 is formed to have a shape complementary to that of the container 10, such that the liner 18 is able to be positioned within the interior 16 of the container 10. In the exemplary illustrated embodiment of FIGS. 1 and 2, the liner 18 includes a body 19 having a bottom wall 20 and a number of side walls 22 joined to one another and extending upwardly from the bottom wall 22 to form an interior 24 of the liner 18. The liner 18 is formed of a lightweight and flexible material, such as a lightweight plastic, and can be formed in any suitable molding process, such as a thermoforming or blow molding process, to achieve the desired shape for the liner 18. The material forming the liner 18 can additionally have a range of thicknesses, from very thin and flexible to relatively stiff materials, and can also be formed in a variety of colors, optionally corresponding to the thickness of the material forming the liner 18. Further, the material selected for forming the liner 18 must necessarily be resistant or inert with respect to the construction material(s) placed within the liner 18, which include but are not limited to a joint compound, stucco, exterior insulation finish system (EIFS) application material, paint, varnish, caulk, adhesive, bonding material, petroleum or solvent.

Each side wall 22 includes an engagement structure 26 positioned thereon opposite the bottom wall 20. The engagement structure 26 allows the respective side wall 22 to be engaged and held against the adjacent side wall 14 of the container 10, thereby preventing any construction material from passing between the side wall 14 of the container 10 and the side wall 22 of the liner 18. The engagement structure 26 can be engaged with the side wall 14 of the container 10 on the interior 16 of the container 10, or can overlap one or more side walls 14 of the container 10, the overlapping forming the engagement between the liner 18 and the container 10. While the engagement structure 26 can take any desired form, in the illustrated exemplary embodiment, the structure 26 is formed a clip 28 integrally formed with the side wall 22 and joined thereto by a living hinge 30 which provides a spring force to frictionally engage the clip 28 with the side wall 14 of the container 10 and maintain the position of the clip 28 relative to the side wall 22. The clip 28 may also be engaged with a suitable and complementary engagement member (not shown) disposed on the side walls 14 of the container 10 generally opposite the bottom wall 12 in order to assist in holding the liner 18 within the container 10. Also, the clip 28 can include an inward taper 31 to facilitate the engagement and disengagement of the clip 28 from the container 10. Further, to facilitate the placement and removal of the liner 18, the clip 28 can include an outwardly extending tab 33 located opposite the hinge 30 to assist in grasping and moving the clip 28 to engage or disengage the container 10. In addition, the clips 28 may include an amount of an adhesive 35 thereon that is positioned against and secured to the exterior surface of the side walls 14 when the clips 28 are engaged with the container 10.

In use, the liner 18 is aligned with the container 10 and placed within the interior 16 of the container 10. The liner 18 is pressed into the interior 16 of the container and the clips 28 simultaneously engage the side walls 14 of the container 10. Once the clips 28 are disposed over, e.g., overlapped over, the side walls 14 of the container 10, as the liner 18 is pressed into the container 10 the clips 28 are deformed against the bias of the hinge 30 in order to position the clips 28 over the ends of the side walls 14 and in engagement with the exterior of the side wall 14. In this manner the liner 18 is engaged with the container 10 to hold the liner 18 in alignment with the container 10 until the clips 28 are disengaged. The joint compound or other construction material can then be placed into the interior 32 of the liner 18 and carried along with the container 10 for use as desired.

Once the material in the liner 18 has been used, the material can be replenished or the liner 18 can be removed from the container 10 by the disengagement of the clips 28 from the side walls 14 of the container 10. Once disengaged, the liner 18 is removed from the interior of the container 10 and disposed of, while another liner 18 is placed into engagement with the container 10, thereby greatly increasing the useful life of the container 10 for carrying construction materials.

Various other embodiments of the present invention are contemplated as being within the scope of the filed claims particularly pointing out and distinctly claiming the subject matter regarded as the invention. 

We claim:
 1. A liner for a construction material container the liner comprising: a) a body; and b) at least one engagement structure disposed on the body and adapted to engage a portion of the construction material container.
 2. The liner of claim 1 wherein the at least one engagement structure includes a clip engageable with the construction material container.
 3. The liner of claim 2 wherein the clip is engageable with an interior surface of the container.
 4. The liner of claim 2 wherein the clip is engageable with an exterior surface of the container.
 5. The liner of claim 4 wherein the clip is biased with respect to the container.
 6. The liner of claim 5 wherein the clip is joined to the body by a living hinge.
 7. The liner of claim 4 wherein the clip includes tapered edges.
 8. The liner of claim 2 further comprising engagement structures disposed on each side wall of the body.
 9. The liner of claim 2 wherein the clip includes a tab disposed opposite the body.
 10. The liner of claim 1 wherein the engagement structure is integrally formed with the body.
 11. The liner of claim 1 wherein the liner is formed of a plastic material.
 12. The liner of claim 1 further comprising an adhesive disposed on the at least one engagement structure.
 13. A method for positioning a protective liner within a construction material container, the method comprising the steps of: providing a liner comprising: i) a body; and ii) at least one engagement structure disposed on the body and adapted to engage a portion of the construction material container; b) placing the body within an interior of the container; and c) engaging the at least one engagement structure with the construction material container.
 14. The method of claim 13 wherein the step of placing the body within the container and engaging the at least one engagement structure with the container occur simultaneously.
 15. A construction material container comprising: a) a container including a number of side walls defining an interior; and b) a liner positioned at least partially within the interior of the container, the liner comprising: i) a body; and ii) at least one engagement structure disposed on the body and engageable with a portion of the construction material container.
 16. The liner of claim 15 wherein the at least one engagement structure includes a clip engageable with the construction material container.
 17. The liner of claim 16 wherein the clip is engageable with an interior surface of the container.
 18. The liner of claim 16 wherein the clip is engageable with an exterior surface of the container.
 19. The liner of claim 18 wherein the clip is biased with respect to the container. 